Introduction
At iFluids Engineering, we conduct thorough Safety Integrity Level (SIL) classification studies to ensure that facilities like the Bharatpur Terminal of Indian Oil Corporation Limited (IOCL) meet the highest standards of operational safety and reliability. The SIL classification process identifies potential risk levels associated with safety instrumented systems (SIS) and recommends measures to mitigate hazards effectively, making critical industrial facilities such as oil and gas terminals essential.
Enhancing Safety and Compliance with SIL Classification
At iFluids Engineering, we conducted a Safety Integrity Level (SIL) Classification Study for the Bharatpur Terminal of Indian Oil Corporation Limited (IOCL) to ensure compliance with IEC 61508 & IEC 61511 standards. This study plays a critical role in evaluating the safety performance of Safety Instrumented Systems (SIS) and reducing operational risks in hazardous environments
- IOCL Bharatpur Terminal (a public sector organization) was commissioned in 1993 & has having facility for the receipt, storage, and dispatch of petroleum products viz Motor Spirit (MS), High-Speed Diesel (HSD), and Ethanol.
- Till 2010, the mode of receipt of products at Bharatpur Terminal was primarily through rakes i.e. rail transportation.
- After the year 2010, the product pipeline from Mathura Refinery to Bharatpur Terminal was commissioned along with the setting up of a Pipeline Station under the premises of Bharatpur Terminal.
- The main activities of the IOCL, Bharatpur Terminal are Receipt, Storage and Delivery. The Terminal receives stores, and distributes Petroleum Products like Ethanol Blended Motor Spirit (EBMS) and High Speed Diesel (HSD).
- The Terminal also handles Ethanol, which is mixed in a proportion of 12% by volume with MS for dispatch.
- The process involves receipt of products through pipeline and tank wagons and storage in above-ground/ underground tanks.
- At the Terminal Blending of high‐performance Petrol and Diesel is done which is followed by the dispatch/filling of different products in Tank Trucks and distribution to retail outlets and various consumers across the districts of Rajasthan.
- All products except Ethanol are received by Pipeline in addition to that Railway Gantry and Tank Truck decantation facilities are also available for receiving the product.
- Ethanol is received through Tank Trucks only.
- Distribution and other related activities carried out at the terminal can be grouped into two parts
- Pipeline Receipt/ Tank Wagon /Tank Truck decantation and receipt in storage tanks
- Filling and distribution through Tank trucks
- MS is stored in an Internal Floating Roof Tank (FRT) and HSD is stored in Cone Roof Tanks (CRT). 04 nos. of underground tanks are provided for the storage of Ethanol and MS.
- All the tanks are provided with CC/brick pitching to the apron and foundations.
- All the storage tanks are provided with 2 Nos. of valves one is ROSOV and the second is DBBV for safety reasons.
- A fire protection system is adequately provided for all tanks.
Objectives of SIL Classification Study
The SIL classification study at the Bharatpur Terminal focused on identifying, analyzing, and classifying the risk levels associated with each critical operation. The primary goals included:

- Risk Assessment: Determining potential hazards and evaluating the risk levels associated with each process, with particular attention to high-stakes process safety scenarios.
- Safety Instrumented System (SIS) Analysis: Analyzing the existing SIS mechanisms and defining the SIL requirements to maintain optimal safety measures.
- Reliability Improvement: Enhancing the reliability of the terminal’s processes by implementing advanced SIL protocols.
As per the scope of this SIL Classification study, Safety Instrumented Functions (SIFs) were identified in the P&IDs and the C&E matrices, relevant to the project, having the following objectives
- Identify potential risks inflicted on people, environment, and assets due to the failure of safety-related systems and associated facilities in the plant to operate on demand.
- Define the basic performance requirements of all Safety Related Instrumented systems to reduce the above risks to “As Low as Reasonably Practicable”.
Layers of Protection Analysis (LOPA) has been used in this study. It is an effective analytical method for determining whether the layers of protection utilized to reduce process risk are enough. LOPA builds upon well‐known process hazard analysis techniques, applying semi‐quantitative measures to the evaluation of the frequency of potential incidents and the probability of failure of the protection layers. It is a simple tool that identifies the safeguards to be considered for risk classification and risk reduction.
Key Outcomes and Recommendations

Our SIL classification study yielded actionable insights and practical recommendations aimed at reducing the risk of safety incidents at the Bharatpur Terminal. Key recommendations included:
- Upgrading Safety Instrumented Functions (SIFs): Implementing robust SIFs for high-risk processes, ensuring optimal control and mitigation of safety-related incidents.
- Improved Maintenance Protocols: Developing structured maintenance plans to align with SIL levels, enhancing the longevity and performance of SIS.
- Enhanced Operator Training: Providing comprehensive training programs to equip operators with the skills required for managing SIS effectively and safely.
Why is SIL Classification Important for Oil & Gas Facilities?
The oil and gas industry operates in high-risk environments, making it essential to implement robust functional safety measures. SIL assessment helps in:
🔹 Preventing catastrophic failures and safety incidents
🔹 Enhancing process reliability and minimizing downtime
🔹 Ensuring adherence to industry safety regulations
Conclusion
By prioritizing SIL classification, IOCL ensures that facilities like the Bharatpur Terminal are equipped with the highest standards in safety risk management. This proactive approach significantly lowers the risk of safety incidents, fostering a safer environment for personnel while supporting environmental protection initiatives.
Our team is committed to delivering comprehensive risk assessments, tailored safety recommendations, and optimized Safety Instrumented System (SIS) reliability. With proven methodologies and a skilled team, each SIL study we conduct results in measurable improvements in operational safety and process reliability, supporting safer, more sustainable industry practices. Together, we can build safer, more resilient operations, safeguarding personnel and the environment for a sustainable future.
iFluids Engineering – Your Trusted Partner in Functional Safety
With years of expertise in process safety and risk assessment, iFluids Engineering specializes in:
✔ SIL Assessment, Verification & Validation
✔ Hazard and Operability (HAZOP) Studies
✔ Layer of Protection Analysis (LOPA)
✔ Quantitative Risk Assessment (QRA)
✔ Process Hazard Analysis (PHA)